Block constructions

ABSTRACT

The invention comprises a method of erecting a wall or like construction from a plurality of similar regular shaped blocks, and a means for carrying out the method, including the utilisation of a pair of spacer or form strips initially maintained in spaced relationship by a plurality of transverse tie members which are preferably separable from the strips, the spacer or form strips being arranged for location between adjacent blocks at the front and rear peripheral edge portions thereof during block erection and having main parts of depth equal to the required spacing of the blocks so that the wall can be erected initially without mortar or other binding materials. In the case of walls erected with hollow blocks the voids can be infilled with concrete after erection of the wall and the strips can be peeled away from the formed joints after the concrete has set to leave a joint of neat appearance.

Thomas [4 1 Sept. 2, 1975 [54] BLOCK CONSTRUCTIONS Robert Edmund Bailey Thomas, 122 Oban St., Wellington, New Zealand 22 Filed: May 31,1974

21 Appl.No.:475,020

[76] Inventor:

OTHER PUBLICATIONS Brick & Clay Record, (Dry Joint Masonry), p. 35, June 1948.

Primary ExaminerJ. Karl Bell Attorney, Agent, or Firm-Ladas, Parry Von Gehr, Goldsmith & Deschamps [5 7] ABSTRACT The invention comprises a method of erecting a wall or like construction from a plurality of similar regular shaped blocks, and a means for carrying out the method, including the utilisation of a pair of spacer or form strips initially maintained in spaced relationship by a plurality of transverse tie members which are preferably separable from the strips, the spacer or form strips being arranged for location between adjacent blocks at the front and rear peripheral edge portions thereof during block erection and having main parts of depth equal to the required spacing of the blocks so that the wall can be erected initially without mortar or other binding materials. In the case of walls erected with hollow blocks the voids can be infilled with concrete after erection of the wall and the strips can be peeled away from the formed joints after the concrete has set to leave a joint of neat appearance.

10 Claims, 8 Drawing Figures PATENTEDSEP 21975 3, 902 296 SHEET 1 [IF 3 PATENTEU 3975 3 902 296 SHEET 2 UF 3 PATENTEB 2|975 3, 902,296

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FIQS.

BLOCK CONSTRUCTIONS This invention relates to block contructions, and more particularly relates to the construction of walls or like structures from regular shaped blocks in particular hollow or cavity blocks of concrete or other material.

Hollow concrete and like blocks are normally erected in tiered relationship in forming a wall by the direct application of mortar to appropriate mating surfaces of the blocks during the laying process, and where additional strength in required the erected wall may be reinforced by filling the block hollows in at least parts of the wall with concrete. It is also known to provide a decorative or temporary wall merely by stacking or laying the blocks without mortar or to utilise such as a mastic adhesive or other adhesive material between blocks in place of the usually applied mortar.

The aforementioned usual or known methods of providing a block wall construction have disadvantages particularly in weather requirements and in the time taken to erect walls using mortar or other adhesive material, and in the skill required in maintaining the blocks in correct alignment and spacing.

An object of this invention is to provide methods and means facilitating and speeding the erection of block walls and in a manner whereby the blocks may be neatly laid and correctly spaced, and whereby an attraetive finish to the block wall may be obtained.

Other objects and advantages of the invention will become apparent from the ensuing description.

According to a first aspect of this invention therefore, there is provided a method of erecting a tiered wall of similar regular shaped blocks comprising the steps of providing an insert spacer or form strip of generally uniform cross-section and a depth equal to the required spacing of adjacent blocks at and between front peripheral edge portions and rear peripheral edge portions of the blocks during laying and without employing mortar during such laying, the spacer or form strips determining the correct spacing and alignment of the blocks, and providing means to secure the blocks in erected relationship. I

According to a second aspect of this invention there is provided a method of erecting a tiered wall of similar regular shaped hollow blocks with upper and lower communicating openings, comprising the steps of providing an insert spacer or form strip of generally uniform cross-section and a depth equal to the required spacing of adjacent blocks at and between front peripheral edge portions and rear peripheral edge portions of the adjacent blocks during laying and without employing mortar during such laying so as to form a cellular wall construction. the spacer or form strips determining the correct spacing and alignment of the blocks, placing a high slump scttable infill material into the block openings at the upper side of the erected wall so as to fill the hollows or cavities of the blocks and fill the spaces between adjacent blocks at the form strips, and allowing the infill material to set and permanently secure the wall in its erected state.

According to a third aspect of this invention, there is provided a means for facilitating the erection of similar regular shaped blocks in a wall construction comprising a pair of spacer or form strips each of a depth equal to the required spacing of adjacent blocks and secured in generally parallel relationship by a plurality of transversely disposed tie members so that said strips are spaced for location between the front peripheral edge portions and rear peripheral edge portions of adjacent block, said form strips being arranged to determine the correct spacing and alignment of the blocks.

FIG. 1 is an end elevational view of one preferred arrangement or assembly of a pair of similar spacer or form strips conjoined by cross tie means,

FIG. 2 is a fragmentary plan view of the form strip assembly shown in FIG. 1,

FIG. 3 is an end view illustrating a modification of the form strip,

FIG. 4 is a fragmentary end elevational view illustrating a modification of the connection between a form strip and a cross tie member,

FIG. 5 is a fragmentary end view illustration of the formation of a right angle joint between two form strips,

FIG. 6 is a front elevational view illustrating a modified spacer or form strip,

FIG. 7 is a fragmentary isometric view illustrating an assembly of rectangular concrete blocks utilising the arrangement of spacer or form strips located according to FIGS. 1, 2 and 5, and,

FIG. 8 is a fragmentary isometric view similar to FIG. 7 but utilising the spacer or form strip of FIG. 6.

Referring firstly to FIGS. 1., 2 and 7, each spacer or form strip, generally indicated by the arrow 1, may be formed by an extrusion process from a suitable plastics material such as a polyethylene or polyvinylchloride material which is of suitable density so as to be firm enough to provide the required support for the blocks 2 during erection without undue deformation, and is flexible and easily cut to length with a sharp tool. Each strip 1 is also either all or at least in outer parts sufficiently resilient so as to be capable of absorbing or conforming to minor surface deformities of the blocks 2.

Preferably both front and rear strips 1 are similar in shape and configuration and each form strip 1 is of generally T cross-section with a centrol rectangular crosssection bar portion 3 of thickness equal to the required block spacing e.g. three-eighths inch, and width which may be for example between A inch and 1 inch. It will be appreciated of course that the invention is not confined to these sizes. The outer side of the strip has a thin flange portion 4, which may be arcuate or bevelled on the outer face, generally normal to the bar portion 3 and forming the T cross-section, the parts of the flange portion 4 at either side of the bar portion 3 extend so as to cover the corner portions 2a of the adjacent blocks 2.

The spacer or form strips 1 are provided for location at the front and rear edge portions of the block 2 and preferably the front and rear strips 1 are conjoined at intervals along their length by tie members 5 so that the spacing between opposed flange portions 4 of strips 1 on opposite sides of the blocks 2 are substantially equal to or fractionally more than the width of the blocks 2 and thus the blocks 2 are easily located and maintained in aligned positions between the flange portions 4 of the pair of strips, thus facilitating and speeding the erection of the blocks 2 into a tiered wall construction.

Location of the block edge or corner portions 211 between the strip flange portions 4 can be further facilitated by splaying the outer parts of the flange portions 4 outwardly from the central bar portions 3 and relative to the block outer faces, as illustrated by way of example in FIG. 3 of the drawings.

The spacer or form strips 1 for each side of the block wall can be formed individually from the same extrusion and subsequently joined together in opposed relationship by transverse tie members of the same or a similar material but in thin flat strips and which have their end portions secured to the spacer or form strip bar portions 3 such as by heat welding or utilising a suitable adhesive. Alternatively, the transverse tie members 5 can be formed integrally with a pair of opposed spacer or form strips 1 such as by a suitable moulding or interrupted extrusion process whereby lengths of the combination form strips 1 and tie members 5 are provided, or it is envisaged that a continuous extrusion including the two opposed spacer or form strips I joined by a continuous integral web can be provided and apertures such as rectangular apertures 6 subsequently provided in the web by a suitable severing means to leave tie members 5 between apertures 6, the cut out web portions being recycled for further use.

In another modification of invention, and referring now to FIG. 4 of the drawings, the spacer or form strip 1 can be formed as a single extrusion and the rectangular bar portion 3 of the spacer or form strip 1 is provided with a longitudinal channel 7 opening to the inner side of the bar portion 3, and separately formed tie strips 5 are provided with end portions arranged to be detachably located in the channels 7 of opposed lengths of the strip 1 as and where required. The channels 7 may have an opening or neck part of lesser width than the main channel part and the tie strip end portions 8 may be enlarged and/or ribbed or be of arrow head formation (when viewed edge-wise) so as to provide a snap tight fit of the end portions 8 in such channels 7 in retaining the two opposed spacer or form strips 1 together; this construction has a particular advantage in that a single size spacer or form strip 1 can be provided and appropriate sized tie members 5 provided to form assemblies for use with the blocks of the various widths.

Continuous lengths of pairs of the form strips 1, with ties 5, can be provided for longitudinal placement between tiers of blocks 2, and separate shorter lengths can be cut off or provided for insertion between the vertical faces of adjacent blocks 2 in any one tier, the end portion of the flange portions 4 of the shorter lengths of strips 1 being cut away as indicated at 9 in FIGS. 5 and 7 in the provision of right angled joints with the respective strip bar portions 3 abutting.

In a further modification, and as illustrated by way of example in FIGS. 6 and 8, it is envisaged that L shaped assemblies of spacer or form strips 10 and transverse tie strips 11 can be provided such as by moulding individually, such L shapes having a long leg 10a equal to the length of each block 2 to be laid plus the required space between adjacent block and a short leg 10!; substantially equal to the height of each block 2 to be laid. Thus, a series of such individual L shaped spacer or former assemblies can be utilised, one for each block 2, in the laying of blocks 2 for a wall.

Temporary jointing of sections of form strips, 1 or 10, (and also tie members 5 or 11) can be effected by use of a suitable adhesive or by utilising staples or like clip fasteners.

Once the wall has been erected with hollow blocks 2 and with the spacer or form strips and assemblies in accordance with this invention, the cellular wall constructed can be filled with a suitable high slump concrete which is allowed to set and provide a solid wall, with the concrete filling the block hollows l2 and the voids 13 between adjacent blocks 2 and abutting the inner opposed edges of opposed spacer or form strips 1 or 10. The form strips 1 or 10 can be left in position to provide a decorative appearance in the wall, but it is intended that the spacer or form strips, 1 or 10, can be subsequently peeled from the joints formed between adjacent blocks 2 after the infill concrete has set to leave a neater joint which does not necessarily require pointing, but leaving a joint which can be easily and quickly pointed if so desired for decorative flushface finishing if required. Where separable tie members 5 (as described with reference to FIG. 4) are provided, the tie member end portions 8 can part from the channels 7 in the respective spacer or form strips 1 due to the flexibility and resilience of material utilised, or if integral or welded or adhered tie strips are provided (as described with reference to FIGS. 1, 2, 6, 7 and 8), the arrangement may provide weakened joints 5a and 11a at the respective bar portions and which can be parted if required when peeling the outer spacer or form strips 1 or 10 away from the joints formed. If so desired similar weakened joints 5a can be provided in the end portions of the tie members 5 according to FIG. 4.

To facilitate removal of the spacer or form strips, 1 or 10, from the transverse tie members, 5 or 11, such members are preferably provided with anchor means which may be in the form of at least one medially positioned projection 14 extending from at least one face of each tie member, 5 or 1 l, for embedment in the concrete infill.

It is well known that in the construction particularly of concrete blocks there can be some irregularities or roughness in the upper and lower surfaces, this being often intended for the purpose of improving the bond between the blocks and the usually utilised mortar. In employing the present invention any such irregularities or deformities can be accommodated by the utilising of plastics materials having a certain amount of resilience. However, particularly for higher wall constructions the spacer or form strips 1 or 10 should be sufficiently firm to solidly support the blocks 2 whilst the infill concrete is setting. Accordingly in preferred constructions of spacer or form strips, 1 or 10, the bar portions 3 thereof are substantially firm or solid so as to be capable of securely supporting tiers of blocks 2 there-above, and irregularities in the portions block upper and lower surfaces engaging such bar portions 3 are accommodated by small thin section longitudinal flanges or ribs 15 which extend from inner end parts of the bar portion surfaces at an inclination thereto and inwardly of the blocks 2. The thinness of the flanges or ribs 15 permits flexing and deformation as required and such flanges or ribs additionally provide effective seals to prevent escape of slurry at the block joints from the infill concrete whilst in the wet state.

In some cases only a temporary and decorative wall may be required and it will of course not be necessary to infill the wall hollows with concrete, but merely rely on the construction of the spacer or form strips with transverse tie members or strips to maintain the blocks in alignment and position. Also, in some cases where a permanent or semi-permanent wall is required but without the strength of a solid concrete wall being required, it is envisaged that an adhesive may be applied to the inner faces of the spacer or form strips mating with the blocks so that the blocks may be adhered thereto. Where infill concrete is not required the invention can be applicable to the erection of walls with solid blocks.

Thus, by this invention, there are provided methods and means for speedily and efficiently erecting a wall with a minimum of skill being required. Particular forms of the invention have been described by way of example. but it will be appreciated that other variations of and modifications to the invention can take place without departing from the scope of the appended claims. For example special shapes of spacer or form strips can be provided as required for use at wall ends, junctions, directional changes and so forth and the invention may be applicable to regular shaped blocks other than the rectangular blocks described and illustrated. Also, whilst reference has been made to a wall construction, the invention may be similarly applied in other constructions e.g. as in a floor, utilising regular shaped blocks.

1 claim:

1. A means for facilitating the erection of similar regular shaped blocks in a wall construction comprising a pair of spacer or form strips each of a depth equal to the required spacing of adjacent blocks and secured in generally parallel relationship by a plurality of transversely disposed tie members so that said spacer or form strips are spaced for location between the front peripheral edge portions and rear peripheral edge portions of adjacent blocks, said spacer or form strips being arranged to determine the correct spacing and alignment of the blocks and having resilient flexible parts capable of accommodating or conforming to irregularities in surface portions of the blocks with which said strips are to be engaged.

2. A means as claimed in claim 1, wherein each spacer or form strip is provided on inner block engaging parts with small thin section resilient and flexible flanges extending longitudinally thereof, said flanges being arranged to accommodate any block surface irregularities.

3. A means as claimed in claim 2 wherein said thin section flanges extend from inner end parts of bar portions of the strips at an inclination to the surfaces thereof and directed inwardly of and towards the blocks.

4. A means as claimed in claim 1 wherein said spacer or form strips each have external longitudinal flange parts arranged for location adjacent the respective front and rear faces of the erected blocks, each strip being of generally T shape cross-section with a central longitudinal bar portion for location between adjacent blocks.

5. A means as claimed in claim 1 wherein the tie members have end portions secured to the strips and have weakened portions at or near their junctions with the spacer or form strips to facilitate separation of the strips from the tie members in leaving the tie members anchored within the erected wall.

6. A means as claimed in claim 1 wherein the pair of spacer or form strips are provided on inner opposed sides with channels or recesses having openings of lesser width than the channel main parts and the tie members have end portions arranged for a tight snap fit within the channels of the respective spacer or form strips.

7. A means as claimed in claim 1 wherein the tie members each have at least one medially positioned projection extending from at least one face thereof and arranged to form an anchor means where the tie member is embedded in concrete filling the voids formed in a wall erected from hollow blocks.

8. A means as claimed in claim 1 wherein each spacer or form strip is of generally L shape when viewed from the front or rear so that a plurality of similar pairs of L shaped strips can be employed in the construction of a wall of similar rectangular blocks with the one leg of each L shape extending for generally the length of the block and the other leg extending for generally the height of a block.

9. A method of erecting a tiered wall of similar regular shaped hollow blocks with upper and lower communicating openings, comprising the steps of locating a means as claimed in claim 1 with the spacer or form strips thereof at and between front peripheral edge portions and rear peripheral edge portions of the adjacent blocks during laying and without employing mortar during such laying so as to form a cellular wall construction, the spacer or form strips determining the correct spacing and alignment of the blocks, placing a high slump settable infill material into the block openings at the upper side of the erected wall so as to fill the hollows or cavities of the blocks and fill the spaces between adjacent blocks at the form strips, and allowing the infill material to set and permanently secure the wall in its erected state.

10. A method as claimed in claim 9 including the additional steps of peeling away the spacer or form strips from the joints formed subsequent to setting of the infill material. 

1. A means for facilitating the erection of similar regular shaped blocks in a wall construction comprising a pair of spacer or form strips each of a depth equal to the required spacing of adjacent blocks and secured in generally parallel relationship by a plurality of transversely disposed tie members so that said spacer or form strips are spaced for location between the front peripheral edge portions and rear peripheral edge portions of adjacent blocks, said spacer or form strips being arranged to determine the correct spacing and alignment of the blocks and having resilient flexible parts capable of accommodating or conforming to irregularities in surface portions of the blocks with which said strips are to be engaged.
 2. A means as claimed in claim 1, wherein each spacer or form strip is provided on inner block engaging parts with small thin section resilient and flexible flanges extending longitudinally thereof, said flanges being arranged to accommodate any block surface irregularities.
 3. A means as claimed in claim 2 wherein said thin section flanges extend from inner end parts of bar portions of the strips at an inclination to the surfaces thereof and directed inwardly of and towards the blocks.
 4. A means as claimed in claim 1 wherein said spacer or form strips each have external longitudinal flange parts arranged for location adjacent the respective front and rear faces of the erected blocks, each strip being of generally T shape cross-section with a central longitudinal bar portion for location between adjacent blocks.
 5. A means as claimed in claim 1 wherein the tie members have end portions secured to the strips and have weakened portions at or near their junctions with the spacer or form strips to facilitate separation of the strips from the tie members in leaving the tie members anchored within the erected wall.
 6. A means as claimed in claim 1 wherein the pair of spacer or form strips are provided on inner opposed sides with channels or recesses having openings of lesser width than the channel main parts and the tie members have end portions arranged for a tight snap fit within the channels of the respective spacer or form strips.
 7. A means as claimed in claim 1 wherein the tie members each have at least one medially positioned projection extending from at least one face thereof and arranged to form an anchor means where the tie member is embedded in concrete filling the voids formed in a wall erected from hollow blocks.
 8. A means as claimed in claim 1 wherein each spacer or form strip is of generally L shape when viewed from the front or rear so that a plurality of similar pairs of L shaped strips can be employed in the construction of a wall of similar rectangular blocks with the one leg of each L shape extending for generally the length of the block and the other leg extending for generally the height of a block.
 9. A method of erecting a tiered wall of similar regular shaped hollow blocks with upper and lower communicating openings, comprising the steps of locating a means as claimed in claim 1 with the spacer or form strips thereof at and between front peripheral edge portions and rear peripheral edge portions of the adjacent blocks during laying and without employing mortar during such laying so as to form a cellular wall construction, the spacer or form strips determining the correct spacing and alignment of the blockS, placing a high slump settable infill material into the block openings at the upper side of the erected wall so as to fill the hollows or cavities of the blocks and fill the spaces between adjacent blocks at the form strips, and allowing the infill material to set and permanently secure the wall in its erected state.
 10. A method as claimed in claim 9 including the additional steps of peeling away the spacer or form strips from the joints formed subsequent to setting of the infill material. 